Articulating dunnage and method of use

ABSTRACT

Articulated dunnage having at least two corner support portions joined along a hinge. The dunnage is movable between an open orientation and a folded configuration. The dunnage may be formed in the open configuration so that the dunnage is biased in the open orientation by the shape memory of the polymeric material. The dunnage is configured to be fitted around a portion of the article and to extend between adjacent corners of the container when in the folded configuration. The present invention also provides a method for packaging using articulating dunnage including the general steps of (a) placing the dunnage in the open configuration on the container over the opening, (b) moving the article into engagement with the dunnage, and (c) inserting the article and dunnage into the container through the opening, the action of inserting the article and dunnage into the container causing the dunnage to move from the open configuration to the closed configuration.

BACKGROUND OF THE INVENTION

The present invention relates to packaging and more particularly to dunnage for containing fragile contents within a container.

Dunnage is widely used in conventional packaging to cradle and support articles within an outer container, such as a cardboard box. The primary function of dunnage is to protect the packaged articles from damage during shipping and handling. Dunnage is available in a wide variety of styles and configurations. For example, expanded foam dunnage is often used to support consumer electronics sold in conventional cardboard boxes, such as computers, DVD players, etc. The configuration of foam dunnage may vary from application to application. In some applications, eight foam corners are provided to be separately fitted into the eight corners of the container to hold the article. In other applications, two foam supports are provided to be separately fitted into the top and bottom of the container to cradle the article from top and bottom. Foam dunnage is available in a variety of other configurations. Although it is lightweight and relatively inexpensive, foam dunnage suffers from a number of problems. For example, foam is bulky and occupies a relatively large amount of space. This can present significant increased inventory costs. Further, foam can be easily broken apart leaving small beads that can get stuck in the packaged article.

Perhaps in response to the disadvantages of foam dunnage, there is an ever-increasing use of polymeric dunnage. Polymeric dunnage is often produced by molding a polymeric sheet to include a plurality of contours that fill the space between the article and the walls of the outer container. Typically, these contours include a variety of bulbous shapes that are configured and positioned to receive and absorb external forces, such as the forces that may result from dropping or other rough handling of the packaged article. Polymeric materials are inexpensive and, if properly designed, provide excellent protection for packaged articles. Polymeric materials are also easily nestable and therefore occupy less space when not in use. This can result in significant inventory savings. Further, polymeric materials are readily recyclable and therefore can provide environmental benefits. Although commonly considered to be a marked improvement over foam dunnage in many aspects, conventional polymeric dunnage suffers from some limitations. For example, it is often desirable to create deep contours in select regions of the polymeric material to provide large cushioning elements for supporting the article in such regions. Unfortunately, deep contours require the stock material to undergo deep draws, which in turn results in significant thinning and weakening of the material in the regions where deep contours are desired. To compensate for this thinning in specific areas, it is typically necessary to increase the overall thickness of the entire sheet of stock material. More specifically, the entire sheet of stock material must be of sufficient thickness so that the areas of greatest thinning remain at an acceptable thickness after the sheet has been formed. As a result, those regions of the dunnage that do not undergo as much thinning are thicker than necessary to perform their function and this additional thickness represents waste material.

Further, significant labor can be associated with the use of conventional dunnage. With conventional dunnage, an individual is typically required to manually place one or more pieces of dunnage in the container before the article is packaged. This may require the individual to reach deep into a container, which can be ergonomically undesirable. The article can then be place in the container, but special care must be taken not to move or damage the dunnage as the article is being inserted. This can be somewhat difficult with heavy articles or loose dunnage pieces. Another option is to fit the dunnage onto the article before it is inserted into the container. This option presents a different set of difficulties because it can be difficult to grab and hold the article while it is fitted with dunnage. It may also be difficult to fit the article into the container when it is fitted with dunnage. Further, it may be difficult to prevent the dunnage from falling off of the article during insertion into the container.

Accordingly, there is an ongoing need for polymeric dunnage that provides more efficient use of material while maintaining the desired level of protection, as well as dunnage that requires less labor during packaging.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome by the present invention which provides articulated polymeric dunnage with at least two corner support portions joined along a hinge. The dunnage is movable between an open orientation and a folded configuration. The dunnage may be formed in the open configuration so that the dunnage is biased in the open orientation by the shape memory of the polymeric material. The dunnage is configured to be fitted around a portion of the article and to extend between adjacent corners of the container when in the folded configuration.

In one embodiment, each corner support portion includes a plurality of contours configured to receive a corner, edge or surface portion (or any combination thereof) of the article to be packaged. In this embodiment, the dunnage is formed in the flat configuration with contours that are generally triangular when viewed in cross section. When the dunnage is articulated into the folded configuration, the contours of the two corner support portions pivot to cooperatively define a generally rectangular opening that will typically be configured to closely receive a portion of the article to be packaged, such as the bottom end of the article.

In another embodiment, each corner support portion includes alternating container engaging surfaces and article engaging surfaces that are joined by support walls. The container engaging surfaces may be configured to directly engage the walls of the container and the article engaging surfaces may be configured to directly engage the article. The support walls interconnect the container and article surfaces.

In one embodiment, the container surfaces may be shaped to define corner recesses. As a result of these recesses, the dunnage does not extend fully into the corners of the container, which leave a void between the corner of the container and the dunnage. Among other things, this allows the corner of the container to deform a certain amount without causing corresponding deformation in the dunnage.

In one embodiment, the dunnage is shaped to provide details that become undercut only when the dunnage is moved into the folded configuration. The details may be configured to partially enclose a portion of the article to be packaged. In effect, these undercut details permit the article and the dunnage to interlock as the dunnage articulates into the folded configuration.

The present invention also provides a method for packaging an article in a container. The method generally includes the steps of (a) providing articulating dunnage that is movable between an open configuration and a closed configuration, (b) providing a container defining an opening, (c) placing the dunnage in the open configuration on the container over the opening, (d) moving the article into engagement with the dunnage, (e) inserting the article and dunnage into the container through the opening, the action of inserting the article and dunnage into the container causing the dunnage to move from the open configuration to the closed configuration.

The present invention provides effective and efficient polymeric dunnage. Unlike conventional hinged dunnage, which may include top, bottom, side and/or end walls that are hinged in the corners, the present invention includes corner support portions that are hinged together at a location between the corners of the container. Because the hinge is not located in the corner, the dunnage can be configured to provide improved protection for the article in the corners of the container, where impact forces can be highly focused. As a result of the articulating nature of the dunnage, the support contours can be formed in a way that provides relatively uniform thinning of the stock material. For example, the contours can be provided with a triangular shape that minimizes localized stretching during forming. When the dunnage is articulated into the folded position, the generally triangular contours pivot to cooperatively define a generally rectangular article receiving void. Further, because the dunnage is configured to close on the article, the dunnage may be provided with contours that become undercut when the dunnage is in the folded configuration. Accordingly, the dunnage can entrap a portion of the article. Also, the present invention can provide support on three sides of an article using only a single hinge. Convention dunnage with corner hinges requires two hinges (one in each corner) to protect three sides of an article. Hinges can negatively impact the protection and strength of the dunnage because they place limits on the shape of the dunnage at and around the hinge locations. Therefore, the reduced number of hinges associated with the present invention provides the opportunity for increased protection and strength.

These and other objects, advantages, and features of the invention will be readily understood and appreciated by reference to the detailed description of the current embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of an embodiment of the dunnage in the open configuration.

FIG. 2 is a top perspective view of an embodiment of the dunnage in the closed configuration.

FIG. 3 is a bottom perspective view of an embodiment of the dunnage in the open configuration.

FIG. 4 is a bottom perspective view of an embodiment of the dunnage in the closed configuration.

FIG. 5 is an exploded perspective view showing a container, article and dunnage in accordance with an embodiment of the present invention.

FIG. 6 is a side view of the dunnage and the article.

FIG. 7 is a front view of the dunnage and the article.

FIG. 8 is a cross sectional view showing the article and the dunnage in the container.

FIG. 9 is a top plan view of the dunnage.

FIG. 10 is a sectional view of the dunnage taken along line X-X of FIG. 6.

FIG. 11 is a sectional view of the dunnage taken along line XI-XI of FIG. 6.

FIG. 12 is a side view of the dunnage in the open configuration.

FIG. 13 is a perspective view showing the dunnage resting over the opening in the container and the article being positioned over the dunnage.

FIG. 14 is a cross sectional view of an alternative embodiment showing the article and the dunnage in the container.

FIG. 15 is a side view of an alternative embodiment in which the dunnage includes four corner support portions.

DESCRIPTION OF THE CURRENT EMBODIMENT

Articulating dunnage in accordance with an embodiment of the present invention is shown in FIGS. 1-4, and is generally designated 10. As shown, the dunnage 10 includes two corner support portions 12 and 14 that are joined along a living hinge 16. The dunnage 10 is selectively movable between an open configuration (See FIGS. 1 and 3) to a closed configuration (See FIGS. 2 and 4) about the living hinge 16. Referring now to FIGS. 5-8, the dunnage 10 is configured to closely receive the article A and to be closely fitted into the container C between adjacent corners. In this embodiment, the article A is packaged in the container C with separate pieces of dunnage 10 and 10′ over the top and bottom of the article A. As perhaps best shown in FIG. 8, the dunnage provides a protective packaging shell between portions of the container C and the article A. The present invention also provides a method for packaging articles A in a container C using articulating dunnage 10. In general, the method includes the steps of resting the dunnage 10 atop the container C and then loading the article A into the container C through the dunnage 10 such that insertion of the article A moves the dunnage 10 into the closed configuration and pushes it down into position within the container 10. For purposes of disclosure, the present invention is described in connection with the packaging of a computer within a conventional cardboard box. The present invention is, however, well suited for use in packaging other articles (single or multiple articles) and for packaging in other types of containers.

Unless otherwise expressly stated, the term “corner” is used herein to refer both to three-wall corners (i.e. convergence of three walls, such as the convergence of the top, front and right side walls) and two-wall corners (i.e. convergence of two walls, such as the convergence of the bottom and right side walls).

As noted above, the present invention is described in connection with the packaging of a computer A in a cardboard box C. FIG. 5 is an exploded perspective view of the assembly showing two pieces of dunnage 10 and 10′ and an article A positioned over an open container C. FIGS. 6 and 7 show the two pieces of dunnage 10 and 10′ fitted onto the article A. FIG. 8 shows the article A and dunnage 10 and 10′ packaged in the container C. In this embodiment, dunnage 10 and 10′ are essentially identical to one another. Accordingly, only dunnage 10 will be described in detail. It should be understood, however, that dunnage 10 and dunnage 10′ may be different as dictated by the application, for example, by the specifications of the article to be packaged or the container in which the article is to be packaged. In some applications, only a single piece of dunnage may be required. In the illustrated embodiment, the container C is a conventional cardboard box. The present invention is not limited to use with cardboard boxes, but may be used with essentially any other form of container. The article A of the illustrated embodiment is a conventional desktop computer tower. The dunnage 10 may be configured for use with essentially any single article or any collection of articles.

As noted above, the dunnage 10 generally includes a pair of corner support portions 12 and 14 that are joined along a hinge 16 (See FIGS. 1-4). The hinge 16 permits that dunnage 10 to be selectively moved between an open configuration (which in the illustrated embodiment is a generally flat configuration; See FIGS. 1 and 3) to a closed configuration (which in the illustrated embodiment is a generally folded configuration; See FIGS. 2 and 4). In the illustrated embodiment, the entire dunnage 10 is integrally formed from a single sheet of stock material (as described in more detail below). In this embodiment, the hinge 16 is a living hinge that is defined by contours (or the absence of contours) in the dunnage 10. It is possible, however, to replace the living hinge 16 with other types of hinges, including without limitation hinges that are not formed integrally with the dunnage 10. A flange 18 extends around the periphery of the dunnage 10. In this embodiment, the flange 18 is defined by a peripheral portion of the stock material that remains unformed during the manufacturing process. As shown, the flange 18 of this embodiment is generally planar when the dunnage 10 is in the flat configuration. For purposes of this disclosure, the term “central plane” will be used to refer to a plane extending through the dunnage that is coincident with the plane defined by the stock material before it was formed. In the case of the illustrated embodiment, the central plane is the plane defined by the flange 18 when the dunnage 10 is in the flat configuration. The design and configuration of the flange 18 may vary from application to application or may be eliminated, if desired. Although the terms “flat,” “open,” “folded,” and “closed” are used throughout the application to refer to different orientations of the dunnage 10, it should be understood that these terms are used as relative terms and are not to be interpreted to require strictly flat, open, folded or closed configurations.

As perhaps best shown in FIGS. 1 and 3, each corner support portion 12 and 14 includes an alternating arrangement of plateaus and valleys that define article surfaces 20 a-h and container surfaces 22 a-g. As the names imply, the article surfaces 20 a-h are configured to engage the article A and the container surfaces 22 a-g are configured to engage the walls of the container C. A plurality of support walls 24 interconnect adjacent article surfaces 20 a-h and container surfaces 22 a-g. The support walls 24 may have any desired draft angle and may be configured to also engage portions of the article A or portions of the container C. In the illustrated embodiment, each article surface 20 a-h includes two generally planar segments 26 and 28 oriented at approximately ninety degrees from one another to define a square corner (See the sectional view of FIG. 10). The size, shape, configuration and number of article surface segments may vary from application to application as desired. For example, contours may be added to the segments to match the shape of the article, such as recesses 56 configured to receive feet on the bottom of article A. An inner recess 30 may be disposed at the vertex of each segment 26 and 28, as shown in FIG. 10. The size, shape and configuration of the inner recesses 30 may vary from application to application. The inner recesses may be entirely eliminated in some applications, if desired, for example, leaving the segments 26 and 28 to directly converge. When the dunnage 10 is in the flat configuration, the article surfaces 20 a-h open upwardly in a generally triangular pattern in a direction substantially perpendicular to the central plane. When the dunnage 10 is in the folded configuration, the article surfaces 20 a-h of the two corner support portions 12 and 14 are pivoted toward one another to cooperatively define a generally rectangular void 32 to receive the article A. Referring now to the sectional view of FIG. 11, each container surface 22 a-g generally includes two generally planar segments 34 and 36 configured to engage adjacent walls of the container C. The size, shape, configuration and number of container surface segments may vary from application to application as desired. The flat segments 34 and 36 may be interconnected by a corner recess 38, as shown in the illustrated embodiment. The corner recesses 38 define a “crush zone” 70 (See FIG. 8) in the corners of the container C where the container C can crumple or otherwise deform without directly engaging the dunnage 10. The corner recesses 38 may be defined by curved (or arcuate) walls, which will provide excellent strength when compared to other geometrical shapes. The size, shape and configuration of the corner recesses 38 may vary from application to application. The corner recesses may be entirely eliminated in some applications, if desired. Although the illustrated dunnage 10 is essentially “square” in the sense that the length of article surface segments 26 is essentially equal to the length of article surface segments 28, the dunnage 10 need not be square. For example, the length of article surface segments 28 may be substantially longer than article surface segment 26 where it is desirable to package wider articles.

Each corner support portion 12 and 14 also includes end contours disposed at opposite ends. In the illustrated embodiment, each corner support portion 12 and 14 includes two end contours 40 a-b and 40 c-d disposed at each end. The end contours 40 a-d of this embodiment are somewhat rectangular in shape and are configured to snuggly engage the end walls of the article A. The size, shape and configuration of the end contours 40 a-d may vary from application to application. The end contours 40 a-d may be entirely eliminated in some application, if desired.

The dunnage 10 may also include limit contours 42 configured to resist over-folding of the dunnage 10. For example, in the illustrated embodiment, the contours 42 of the two support portions 12 and 14 are configured to abut once the dunnage 10 has been moved into the folded configuration (See FIGS. 10 and 11). More specifically, in this embodiment, the article surfaces 20 b-g extend above the central plane of the dunnage 10. As a result, short end walls 44 are defined at opposite transverse ends of each article surface 20 b-g. When the dunnage 10 is folded, the end walls 44 of adjacent corner support portions 12 and 14 engage one another to resist over-folding and improve the overall structural integrity of the base 46 when the dunnage 10 is in the folded configuration. Although the limit contours 42 of the illustrated embodiment extend from the article surfaces 20 b-g, the limit contours 42 may be formed in other parts of the dunnage 10. For example, the limit contours may be formed in the end contours 40 of the dunnage 10 (not shown) or may be extensions of the container surfaces 22 a-g (not shown).

As noted above, FIG. 8 is a cross-sectional view taken through the packaged container C. This illustration shows the interrelationship between the dunnage 10 and 10′, article A and container C. The bottom dunnage 10 is essentially coextensive with the bottom of the container C and supports the bottom of the article A inwardly from all sides of the container C. The top dunnage 10′ is essentially coextensive with the top of the container C and supports the top of the article A inwardly from all sides of the container C. The corner recesses 38 of this embodiment are generally arcuate providing space between the corner of the container C and the dunnage 10 and 10′ while at the same time providing a relatively strong bridge between paired segments 34 and 36 of the container surfaces 22 a-g.

In one embodiment, the dunnage 10 and 10′ is manufactured by forming an essentially planar sheet of polymeric material (not shown) using conventional molding techniques and apparatus (not shown). For example, the stock material may be vacuum molded using conventional vacuum molding equipment. In this embodiment, a generally conventional vacuum mold (not shown) is used to form the dunnage 10 and 10′. The dunnage 10 and 10′ is molded from a sheet of recycled polyethylene terephthalate (RPET) in the described embodiment. However, essentially any thermoformable material may be used, including without limitation HDPE, PETG, PVC and LDPE. In this embodiment, a vacuum mold (not shown) is provided with contours corresponding with those of the dunnage 10 as described and illustrated. The stock material may be heated and drawn over the vacuum mold in a conventional manner. In one embodiment, the stock material is clamped at its periphery, heated to the appropriate temperature and then drawn over the mold. The peripheral edges of the stock material may be trimmed after molded to provide the flange 18.

The present invention is also directed to a method for packaging articles in a container using articulating dunnage. With reference to the embodiment illustrated above, the method generally includes the steps of: (a) providing articulating dunnage 10 that is movable between an open configuration and a closed configuration, (b) providing a container C defining an opening C1 through which the article A is to be inserted into the container C, (c) placing the dunnage 10 in the open configuration on the container C over the opening C1, (d) moving the article A into engagement with the dunnage 10, (e) inserting the article A and dunnage 10 into the container C through the opening C1 such that the action of inserting the article A and dunnage 10 into the container C causes the dunnage to move from the open configuration to the closed configuration. FIG. 13 shows the dunnage 10 resting on the container C (and more specifically on the flaps C2 of the container C) over the opening C1. The article A is engaged with the dunnage 10 and ready to be inserted into the container C in the direction denoted by arrow D. As the article A is lowered into the container C beyond the point shown in FIG. 13, interaction with the container C will cause the dunnage 10 to bend about hinge 16 and close around the bottom of the article A. The dunnage 10 will continue to progressively close until it reaches the closed configuration. In the illustrated embodiment, the limit contours 42 will abut one another as the dunnage 10 reaches the closed configuration. The article A and dunnage 10 are lowered into the container C until the dunnage 10 is firmly seated on the bottom of the container C with the corner support portions 12 and 14 occupying the corners of the container C.

In an alternative embodiment, the dunnage 210 may include contours 260 that become undercut as the dunnage 210 moves from the open configuration to the closed configuration. The undercut contours 260 permit the dunnage 210 to be designed to interlock with the article A′. For example, as shown in FIG. 14, each corner support portion 212 and 214 of the dunnage 210 may include contours 260 that extend into corresponding contours in the article A. The size, shape, configuration and number of undercut contours may vary from application to application as desired.

Although the present invention is described above in connection with dunnage 10 having two corner support portions 12 and 14, the dunnage may alternatively include additional corner support portions. For example, as shown in FIG. 15, the dunnage 310 may include four corner support portions 312, 314, 316 and 318 that are joined along hinges 320, 322 and 324. In this embodiment, a single piece of dunnage 310 can be closed fully around the article A to cradle the article from all sides.

The above description is that of the current embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. 

1. An article of articulating dunnage for use in a container comprising: a first corner support portion to be fitted into a first corner of the container; a second corner support portion to be fitted into a second corner of the container; and a hinge interconnecting said first corner support portion and said second corner support portion, said hinge positioned to be located between the first corner and the second corner when the dunnage is fitted into the container, said hinge permitting said dunnage to be selectively movable between an open configuration and a closed configuration.
 2. The dunnage of claim 1 wherein the first corner of the container and the second corner of the container are adjacent corners.
 3. The dunnage of claim 1 wherein the dunnage includes limit contours to prevent articulation of the dunnage beyond a predetermined orientation.
 4. The dunnage of claim 1 wherein said dunnage is movable between an open configuration in which each of said corner support portions defines a generally triangular-shaped article receiving opening and a closed configuration in which said corner support portions cooperatively define a generally rectangular-shaped article receiving opening.
 5. The dunnage of claim 1 wherein each corner support portion includes a plurality of alternating article surfaces and container surfaces interconnected by support walls.
 6. The dunnage of claim 5 wherein said container surfaces define limit contours to prevent articulation of the dunnage beyond a predetermined orientation.
 7. The dunnage of claim 4 wherein each of said container surfaces defines a corner recess.
 8. The dunnage of claim 4 wherein each of said article surfaces defines an inner recess.
 9. The dunnage of claim 7 wherein each of said container surfaces include a first segment to engage a first wall of the container and a second segment to engage a second wall of the container, and wherein said corner recesses are defined by an arcuate segment interconnecting said first segment and said second segment.
 10. The dunnage of claim 1 wherein at least one of said corner support portions includes an undercut contour that is undercut with respect to a direction in which an article is moved into and out of the dunnage, said undercut contour being undercut when the dunnage is in the closed configuration but not undercut when the dunnage is in the open configuration.
 11. A packaging combination comprising: a container having a first corner and a second corner, said first corner being adjacent to said second corner; and articulating dunnage selectively movable between an open configuration and a closed configuration, said dunnage fitted into said container in said closed configuration, said dunnage including a first corner support portion fitted into said first corner of said container and a second corner support portion fitted into said second corner of said container, said first corner support portion connected to said second corner support portion by a hinge, said hinge disposed between said first corner and said second corner and permitting relative motion between said first corner support portion and said second corner support portion, whereby said dunnage is selectively movable between an open position and a closed position.
 12. The combination of claim 11 wherein said first corner and said second corner are adjacent corners, said hinge being located between said first corner and said second corner.
 13. The combination of claim 12 wherein said dunnage is movable between an open configuration in which each of said corner support portions defines a generally triangular-shaped article receiving opening and a closed configuration in which said corner support portions cooperatively define a generally rectangular-shaped article receiving opening.
 14. The combination of claim 13 wherein said dunnage includes limit contours that prevent said dunnage from being articulated beyond a predetermined limit.
 15. The combination of claim 14 wherein said dunnage includes a plurality of alternating article surfaces and container surfaces joined by support walls.
 16. The combination of claim 15 wherein said container surfaces include a first container-engaging segment, a second container-engaging segment and an arcuate segment joining said first and second container-engaging segments.
 17. The combination of claim 11 wherein at least one of said corner support portions includes an undercut contour that is undercut with respect to a direction in which said article is moved into and out of said dunnage, said undercut contour being undercut when said dunnage is in the closed configuration but not undercut when said dunnage is in the open configuration.
 18. A method for packing an article within a container, comprising the steps of: providing articulating dunnage movable between an open configuration and a closed configuration; providing a container having an open end; placing the dunnage over the container resting on the open end; moving an article into engagement with the dunnage; and inserting the article and dunnage into the container through the opening, the action of inserting the article and dunnage into the container causing the dunnage to move from the open configuration to the closed configuration, the movement of the dunnage into the closed configuration causing the dunnage to close about at least a portion of the article.
 19. The method of claim 18 wherein the dunnage includes a pair of corner supports joined by a hinge, each of the corner support portions defines a generally triangular-shaped article receiving opening when the dunnage is in the open configuration and wherein the corner support portions cooperatively define a generally rectangular-shaped article receiving opening when the dunnage is in the closed configuration.
 20. The method of claim 19 wherein said inserting step is further defined as inserting the article and the dunnage into the container through the opening until the corner support portions are seated in adjacent corners of the container. 